Cartridge assembly for faucet

ABSTRACT

The present invention provides a cartridge assembly for a faucet that provides improved flow rate, flow modulation, and particulate passage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. Non-Provisionalapplication Ser. No. 13/804,244, filed Mar. 14, 2013, the entiredisclosure of which is hereby incorporated by reference, which claimsthe benefit of U.S. Provisional Application No. 61/684,699, filed Aug.17, 2012, the entire disclosure of which is hereby incorporated byreference.

FIELD

The present invention relates generally to a cartridge assembly for afaucet, and, more particularly, to a cartridge assembly for a faucetthat provides improved flow rate, flow modulation, and particulatepassage.

BACKGROUND

In a faucet, disks are installed in a cartridge assembly for the faucet.The size and shape of the openings in the disks determine the flow rate,the flow modulation, and the particulate passage through the cartridgeassembly. Prior disks typically optimize one of these features whilecompromising the other features.

SUMMARY

The present invention provides a cartridge assembly for a faucet thatprovides improved flow rate, flow modulation, and particulate passage.

In an exemplary embodiment, the cartridge assembly includes a cartridgeshell. The cartridge shell includes a first end and a second end. Thecartridge shell has an exterior surface. The cartridge shell has aninterior. The cartridge shell includes a pair of openings extending fromthe interior through the exterior surface between the first end and thesecond end. The cartridge assembly includes a stem. The stem is operableto be at least partially disposed within the cartridge shell. Thecartridge assembly includes a moveable disk. The moveable disk isoperable to be disposed within the cartridge shell. The moveable diskincludes a top side and a bottom side. The moveable disk furtherincludes a pair of openings extending from the top side through thebottom side. The openings in the moveable disk are symmetrical across acenter line of the openings. The cartridge assembly includes a fixeddisk. The fixed disk is operable to be disposed within the cartridgeshell. The fixed disk includes a top side and a bottom side. The fixeddisk further includes a pair of openings extending from the top sidethrough the bottom side. The openings in the fixed disk are symmetricalacross a center line of the openings. The stem is operable to beconnected to the moveable disk so that rotation of the stem causesrotation of the moveable disk. The bottom side of the moveable disk isoperable to abut the top side of the fixed disk. Flow through thecartridge assembly flows through the openings in the fixed disk andthrough the openings in the moveable disk and exits through the openingsin the cartridge shell. The openings in the moveable disk and theopenings in the fixed disk are configured so that a flow rate throughthe cartridge assembly, at three bars of flowing pressure, from an openposition at a stem rotation of approximately fifteen degrees to an openposition at a stem rotation of approximately seventy-five degrees,follows an S-curve.

In another exemplary embodiment, the cartridge assembly includes acartridge shell. The cartridge shell includes a first end and a secondend. The cartridge shell has an exterior surface. The cartridge shellhas an interior. The cartridge shell includes a pair of openingsextending from the interior through the exterior surface between thefirst end and the second end. The cartridge assembly includes a stem.The stem is operable to be at least partially disposed within thecartridge shell. The cartridge assembly includes a moveable disk. Themoveable disk is operable to be disposed within the cartridge shell. Themoveable disk includes a top side and a bottom side. The moveable diskfurther includes a pair of openings extending from the top side throughthe bottom side. The openings in the moveable disk are symmetricalacross a center line of the openings. The cartridge assembly includes afixed disk. The fixed disk is operable to be disposed within thecartridge shell. The fixed disk includes a top side and a bottom side.The fixed disk further includes a pair of openings extending from thetop side through the bottom side. The openings in the fixed disk aresymmetrical across a center line of the openings. The stem is operableto be connected to the moveable disk so that rotation of the stem causesrotation of the moveable disk. The bottom side of the moveable disk isoperable to abut the top side of the fixed disk. Flow through thecartridge assembly flows through the openings in the fixed disk andthrough the openings in the moveable disk and exits through the openingsin the cartridge shell. The openings in the moveable disk and theopenings in the fixed disk are configured so that a flow rate throughthe cartridge assembly, at three bars of flowing pressure, from an openposition at a stem rotation of approximately fifteen degrees to an openposition at a stem rotation of approximately forty-five degrees,increases along a gradual upwardly sloped curve. The openings in themoveable disk and the openings in the fixed disk are configured so thata flow rate through the cartridge assembly, at three bars of flowingpressure, from the open position at the stem rotation of approximatelyforty-five degrees to an open position at a stem rotation ofapproximately seventy-five degrees, increases along a steep upwardlysloped curve.

In another exemplary embodiment, the cartridge assembly includes acartridge shell. The cartridge shell includes a first end and a secondend. The cartridge shell has an exterior surface. The cartridge shellhas an interior. The cartridge shell includes a pair of openingsextending from the interior through the exterior surface between thefirst end and the second end. The cartridge assembly includes a stem.The stem is operable to be at least partially disposed within thecartridge shell. The cartridge assembly includes a moveable disk. Themoveable disk is operable to be disposed within the cartridge shell. Themoveable disk includes a top side and a bottom side. The moveable diskfurther includes a pair of openings extending from the top side throughthe bottom side. The openings in the moveable disk are symmetricalacross a center line of the openings. The cartridge assembly includes afixed disk. The fixed disk is operable to be disposed within thecartridge shell. The fixed disk includes a top side and a bottom side.The fixed disk further includes a pair of openings extending from thetop side through the bottom side. The openings in the fixed disk aresymmetrical across a center line of the openings. The stem is operableto be connected to the moveable disk so that rotation of the stem causesrotation of the moveable disk. The bottom side of the moveable disk isoperable to abut the top side of the fixed disk. Flow through thecartridge assembly flows through the openings in the fixed disk andthrough the openings in the moveable disk and exits through the openingsin the cartridge shell. The openings in the moveable disk and theopenings in the fixed disk are configured so that there are two zones ofcontrol. In a first zone, from an open position at a stem rotation ofapproximately fifteen degrees to an open position at a stem rotation ofapproximately forty-five degrees, a flow rate increases at a gradualrate and there is a high degree of control over flow modulation. In asecond zone, from the open position at the stem rotation ofapproximately forty-five degrees to an open position at a stem rotationof approximately seventy-five degrees, a flow rate increases at a steeprate and there is a low degree of control over flow modulation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cartridge assembly installed in avalve body according to an exemplary embodiment of the presentinvention;

FIG. 2 is an exploded perspective view of the cartridge assembly of FIG.1, including a moveable disk and a fixed disk;

FIG. 3 is a bottom plan view of the cartridge assembly of FIG. 2;

FIG. 4 is a cross-sectional view of the cartridge assembly of FIG. 2along the line A-A in FIG. 3;

FIG. 5 is a cross-sectional view of the cartridge assembly of FIG. 2along the line B-B in FIG. 3;

FIGS. 6 a-6 d are views of the moveable disk of FIG. 2-FIG. 6 a is a topplan view, FIG. 6 b is a bottom plan view, FIG. 6 c is a frontelevational view, and FIG. 6 d is a side elevational view;

FIGS. 7 a-7 d are views of the fixed disk of FIG. 2-FIG. 7 a is a bottomplan view, FIG. 7 b is a top plan view, FIG. 7 c is a front elevationalview, and FIG. 7 d is a side elevational view;

FIGS. 8 a-8 j are bottom plan views of the moveable disk of FIGS. 6 a-6d and the fixed disk of FIGS. 7 a-7 d, as assembled in the cartridgeassembly of FIG. 2, at varying degrees of handle and stem rotation—FIG.8 a is at zero degrees (0°) rotation, FIG. 8 b is at ten degrees (10°)rotation, FIG. 8 c is at twenty degrees (20°) rotation, FIG. 8 d is atthirty degrees (30°) rotation, FIG. 8 e is at forty degrees (40°)rotation, FIG. 8 f is at fifty degrees (50°) rotation, FIG. 8 g is atsixty degrees (60°) rotation, FIG. 8 h is at seventy degrees (70°)rotation, FIG. 8 i is at eighty degrees (80°) rotation, and FIG. 8 j isat ninety degrees (90°) rotation;

FIG. 9 is a chart showing maximum flow rate data for the cartridgeassembly of FIG. 2, including the moveable disk of FIGS. 6 a-6 d and thefixed disk of FIGS. 7 a-7 d;

FIG. 10 is a chart showing flow modulation data for the cartridgeassembly of FIG. 2, including the moveable disk of FIGS. 6 a-6 d and thefixed disk of FIGS. 7 a-7 d; and

FIG. 11 is a graph showing a flow modulation curve for the flowmodulation data of FIG. 10.

DETAILED DESCRIPTION

The present invention provides a cartridge assembly for a faucet thatprovides improved flow rate, flow modulation, and particulate passage.An exemplary embodiment of a cartridge assembly 10 of the presentinvention is shown in FIGS. 1-5.

In an exemplary embodiment, as illustrated in FIG. 1, the cartridgeassembly 10 is installed in a valve body 12. In an exemplary embodiment,as illustrated in FIGS. 2-5, the cartridge assembly 10 includes acartridge shell 14, a stem seal 16, a stem 18, a moveable disk 20, afixed disk 22, a base seal 24, a base seal support 26, and a shell seal28. Cartridge assemblies and valve bodies are well-known in the art and,therefore, only the relevant components of the cartridge assembly 10 andthe valve body 12 will be described in greater detail.

In the illustrated embodiment, as best shown in FIGS. 4 and 5, thecartridge shell 14 includes a first end 30 and a second end 32. Thecartridge shell 14 has an exterior surface 34 with a generallycylindrical shape. The cartridge shell 14 has an interior 36 with acentral longitudinal axis 38 extending through a center 40 of theinterior 36 from the first end 30 to the second end 32. The cartridgeshell 14 can be formed of plastic, metal, or any other suitablematerial.

In the illustrated embodiment, as best shown in FIG. 1, the valve body12 includes a first end 42 and a second end 44. The valve body 12 has anexterior surface 46 with a generally cylindrical shape. The valve body12 has an interior surface 48 with a generally cylindrical shape. Theinterior surface 48 of the valve body 12 generally corresponds to theexterior surface 34 of the cartridge shell 14. In an exemplaryembodiment, the valve body 12 is for use in a two-handle faucet. Thevalve body 12 can be formed of plastic, metal, or any other suitablematerial.

In an exemplary embodiment, as illustrated in FIGS. 6 a-6 d, themoveable disk 20 includes a top side 50 and a bottom side 52.Additionally, the moveable disk 20 includes a pair of openings 54extending from the top side 50 through the bottom side 52. In theillustrated embodiment, the openings 54 include a base portion 56 and aneck portion 58 extending radially outwardly from the base portion 56.The base portion 56 is wider than the neck portion 58. In theillustrated embodiment, the openings 54 are symmetrical across a centerline 60 of the openings 54. Since the openings 54 are symmetrical, themoveable disk 20 can be rotated in a clockwise or counterclockwisedirection and, thus, can be used in a left-hand or a right-handinstallation. In an exemplary embodiment, the moveable disk 20 is formedof ceramic material. In an exemplary embodiment, the moveable disk 20 isformed of aluminum oxide. However, the moveable disk 20 could be formedof other suitable materials.

In an exemplary embodiment, as illustrated in FIGS. 7 a-7 d, the fixeddisk 22 includes a top side 62 and a bottom side 64. Additionally, thefixed disk 22 includes a pair of openings 66 extending from the top side62 through the bottom side 64. In the illustrated embodiment, theopenings 66 include a base portion 68 and a neck portion 70 extendingradially inwardly from the base portion 68. The base portion 68 is widerthan the neck portion 70. In the illustrated embodiment, the openings 66are symmetrical across a center line 72 of the openings 66. Since theopenings 66 are symmetrical, the fixed disk 22 can be rotated in aclockwise or counterclockwise direction and, thus, can be used in aleft-hand or a right-hand installation. In an exemplary embodiment, thefixed disk 22 is formed of ceramic material. In an exemplary embodiment,the fixed disk 22 is formed of aluminum oxide. However, the fixed disk22 could be formed of other suitable materials.

In the illustrated embodiment, as best shown in FIGS. 2 and 4, thecartridge shell 14 includes a pair of openings 74 extending from theinterior 36 through the exterior surface 34 between the first end 30 andthe second end 32 of the cartridge shell 14. Additionally, the stem 18includes a first end 76 and a second end 78. The stem 18 includes a pairof recesses 80 near the second end 78 of the stem 18. Further, themoveable disk 20 includes a pair of recesses 82 in the top side 50adjacent the openings 54 in the moveable disk 20.

In the illustrated embodiment, as best shown in FIGS. 2, 4, and 5, ahandle (not shown) is connected to the first end 76 of the stem 18, andthe second end 78 of the stem 18 is connected to the top side 50 of themoveable disk 20. Additionally, the bottom side 52 of the moveable disk20 abuts the top side 62 of the fixed disk 22. Rotation of the handlecauses rotation of the stem 18. Rotation of the stem 18 causes rotationof the moveable disk 20. Rotation of the moveable disk 20 relative tothe fixed disk 22 controls the flow of fluid (typically, water) throughthe faucet.

Fluid flowing through the cartridge assembly 10 enters through the baseseal 24 and the base seal support 26 in the second end 32 of thecartridge shell 14. Fluid flows through the openings 66 in the fixeddisk 22 and through the openings 54 in the moveable disk 20. Fluid thenflows through the recesses 82 in the moveable disk 20 and through therecesses 80 in the stem 18. Fluid exits through the openings 74 in thecartridge shell 14.

During operation of the faucet, when the handle and the stem 18 are inthe completely closed position at a handle and stem 18 rotation ofapproximately zero degrees (0°), the openings 54 in the moveable disk 20and the openings 66 in the fixed disk 22 do not overlap. As the handleand the stem 18 are rotated, the openings 54 in the moveable disk 20begin to overlap with the openings 66 in the fixed disk 22. As thehandle and the stem 18 are continually rotated, the amount of overlapbetween the openings 54 in the moveable disk 20 and the openings 66 inthe fixed disk 22 increases. When the handle and the stem 18 are rotatedto a completely open position at a handle and stem 18 rotation ofapproximately ninety degrees (90°), the openings 54 in the moveable disk20 are at a maximum overlap with the openings 66 in the fixed disk 22.

FIGS. 8 a-8 j show the moveable disk 20 and the fixed disk 22 withvarying amounts of overlap between the openings 54 in the moveable disk20 and the openings 66 in the fixed disk 22, at ten degree (10°)increments of handle and stem 18 rotation, starting at the completelyclosed position at a handle and stem 18 rotation of approximately zerodegrees (0°) through the completely open position at the handle and thestem 18 rotation of approximately ninety degrees (90°).

The size and shape of the openings 54 in the moveable disk 20 and theopenings 66 in the fixed disk 22 determine the flow rate, the flowmodulation, and the particulate passage through the cartridge assembly10.

The flow rate is the amount of fluid (typically, water) that can flowthrough the cartridge assembly 10 when the handle and the stem 18 are inan open position. The maximum flow rate is the maximum amount of fluidthat can flow through the cartridge assembly 10 when the handle and thestem 18 are in a completely open position. It is desirable to have ahigh maximum flow rate.

FIG. 9 is a chart showing maximum flow rate data for the cartridgeassembly 10, including the moveable disk 20 and the fixed disk 22. Thechart shows the maximum flow rate through the cartridge assembly 10, atten pounds per square inch (10 psi) increments of flowing pressure,starting at approximately zero pounds per square inch (0 psi) of flowingpressure through one-hundred ten pounds per square inch (110 psi) offlowing pressure.

The flow modulation is the ability to control the flow rate over a rangeof handle and stem 18 positions. It is desirable to accurately controlthe flow rate over a greater range of handle and stem 18 positions. Inan exemplary embodiment, the flow rate can be accurately controlled overa range of at least thirty degrees (30°) of handle and stem 18 rotation.

FIG. 10 is a chart showing flow modulation data for the cartridgeassembly 10, including the moveable disk 20 and the fixed disk 22. Thechart shows the flow rate through the cartridge assembly 10, at threebars (3 bars) of flowing pressure, at five degree (5°) increments ofhandle and stem 18 rotation, from the completely closed position at astem rotation of approximately zero degrees (0°), through the completelyopen position at a stem rotation of approximately ninety degrees (90°),and back to a completely closed position at a stem rotation ofapproximately one-hundred eighty degrees (180°). FIG. 11 is a graphshowing a flow modulation curve for the cartridge assembly 10, includingthe moveable disk 20 and the fixed disk 22, based on the flow modulationdata of FIG. 10.

The data for FIGS. 9-11 was obtained from tests conducted on thecartridge assembly 10 of FIG. 2, including the moveable disk 20 of FIGS.6 a-6 d and the fixed disk 22 of FIGS. 7 a-7 d. The cartridge assembly10 was installed in a test fixture. The test fixture was a steelthreaded housing that encased the cartridge assembly 10. There was aseal between the cartridge assembly 10 and the inlet of the testfixture, but the outlet was open to atmosphere (i.e., there were nodischarge restrictions). The flow rate was measured using a flow benchwith a capability of flowing zero to twenty gallons per minute (0-20GPM).

The particulate passage is the ability to pass particulate through thecartridge assembly 10. It is desirable to pass large particulate throughthe cartridge assembly 10.

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that there aretwo (2) zones of control over the flow rate, the flow modulation, andthe particulate passage, as illustrated in FIGS. 10 and 11. In the firstzone, the flow rate increases at a gradual rate, there is a high degreeof control over the flow modulation, and there is a limited ability topass particulate. In the second zone, the flow rate increases at a steeprate, there is a low degree of control over the flow modulation, andthere is an expansive ability to pass particulate.

In an exemplary embodiment, the first zone is a range from an openposition at a stem 18 rotation of approximately fifteen degrees (15°) toan open position at a stem 18 rotation of approximately forty-fivedegrees (45°), and the second zone is a range from the open position atthe stem 18 rotation of approximately forty-five degrees (45°) to anopen position at a stem 18 rotation of approximately seventy-fivedegrees (75°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that an averageflow rate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, in the second zone, for each stem 18 rotation ofapproximately five degrees (5°), is greater than an average flow ratethrough the cartridge assembly 10, at three bars (3 bars) of flowingpressure, in the first zone, for each stem 18 rotation of approximatelyfive degrees (5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the averageflow rate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, in the second zone, for each stem 18 rotation ofapproximately five degrees (5°), is at least approximately one-hundredtwenty-five percent (125%) of the average flow rate through thecartridge assembly 10, at three bars (3 bars) of flowing pressure, inthe first zone, for each stem 18 rotation of approximately five degrees(5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the averageflow rate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, in the second zone, for each stem 18 rotation ofapproximately five degrees (5°), is at least approximately one-hundredfifty percent (150%) of the average flow rate through the cartridgeassembly 10, at three bars (3 bars) of flowing pressure, in the firstzone, for each stem 18 rotation of approximately five degrees (5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the averageflow rate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, in the second zone, for each stem 18 rotation ofapproximately five degrees (5°), is at least approximately one-hundredseventy-five percent (175%) of the average flow rate through thecartridge assembly 10, at three bars (3 bars) of flowing pressure, inthe first zone, for each stem 18 rotation of approximately five degrees(5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the maximumflow rate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, at the completely open position at a stem 18 rotationof approximately ninety degrees (90°), is approximately six gallons perminute (6 GPM).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately fifteen degrees (15°) to the open position at the stem 18rotation of approximately seventy-five degrees (75°), follows anS-curve, as illustrated in FIG. 11.

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately fifteen degrees (15°) to the open position at the stem 18rotation of approximately forty-five degrees (45°), increases along agradual upwardly sloped curve, as illustrated in FIG. 11.

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately fifteen degrees (15°) to the open position at the stem 18rotation of approximately forty-five degrees (45°), increases at anaverage of less than approximately six-tenths gallons per minute (0.6GPM) for each stem 18 rotation of approximately five degrees (5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately fifteen degrees (15°) to the open position at the stem 18rotation of approximately forty-five degrees (45°), increases at anaverage of less than approximately five-tenths gallons per minute (0.5GPM) for each stem 18 rotation of approximately five degrees (5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately fifteen degrees (15°) to the open position at the stem 18rotation of approximately forty-five degrees (45°), increases at anaverage of less than approximately four-tenths gallons per minute (0.4GPM) for each stem 18 rotation of approximately five degrees (5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately fifteen degrees (15°) to the open position at the stem 18rotation of approximately forty-five degrees (45°), increases at anaverage of approximately three-tenths gallons per minute (0.3 GPM) foreach stem 18 rotation of approximately five degrees (5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately forty-five degrees (45°) to the open position at the stem18 rotation of approximately seventy-five degrees (75°), increases alonga steep upwardly sloped curve, as illustrated in FIG. 11.

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, from the open position at the stem 18 rotation ofapproximately forty-five degrees (45°) to the open position at the stem18 rotation of approximately seventy-five degrees (75°), increases at anaverage of approximately sixth-tenths gallons per minute (0.6 GPM) foreach stem 18 rotation of approximately five degrees (5°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, at the open position at the stem 18 rotation ofapproximately forty-five degrees (45°), is less than approximately fourgallons per minute (4 GPM).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, at the open position at the stem 18 rotation ofapproximately forty-five degrees (45°), is less than approximately threegallons per minute (3 GPM).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, at the open position at the stem 18 rotation ofapproximately forty-five degrees (45°), is less than approximately twogallons per minute (2 GPM).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach three gallons per minute (3 GPM) untilan open position at a stem 18 rotation of at least approximately fortydegrees (40°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach three gallons per minute (3 GPM) untilthe open position at the stem 18 rotation of at least approximatelyforty-five degrees (45°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach three gallons per minute (3 GPM) untilan open position at a stem 18 rotation of at least approximately fiftydegrees (50°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach four gallons per minute (4 GPM) untilthe open position at the stem 18 rotation of at least approximatelyforty-five degrees (45°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach four gallons per minute (4 GPM) untilthe open position at the stem 18 rotation of at least approximatelyfifty degrees (50°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach four gallons per minute (4 GPM) untilan open position at a stem 18 rotation of at least approximatelyfifty-five degrees (55°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach five gallons per minute (5 GPM) untilthe open position at the stem 18 rotation of at least approximatelyfifty-five degrees (55°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach five gallons per minute (5 GPM) untilan open position at a stem 18 rotation of at least approximately sixtydegrees (60°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that the flowrate through the cartridge assembly 10, at three bars (3 bars) offlowing pressure, does not reach five gallons per minute (5 GPM) untilan open position at a stem 18 rotation of at least approximatelysixty-five degrees (65°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that particulatein the shape of a circular ball, having a diameter of six-hundredthsinch (0.06 in), can pass through the cartridge assembly 10 when thehandle and the stem 18 are in the completely open position at a handleand stem 18 rotation of approximately ninety degrees (90°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that particulatein the shape of a circular ball, having a diameter of seven-hundredthsinch (0.07 in), can pass through the cartridge assembly 10 when thehandle and the stem 18 are in the completely open position at a handleand stem 18 rotation of approximately ninety degrees (90°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that particulatein the shape of a circular ball, having a diameter of eight-hundredthsinch (0.08 in), can pass through the cartridge assembly 10 when thehandle and the stem 18 are in the completely open position at a handleand stem 18 rotation of approximately ninety degrees (90°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that particulatein the shape of a circular ball, having a diameter of nine-hundredthsinch (0.09 in), can pass through the cartridge assembly 10 when thehandle and the stem 18 are in the completely open position at a handleand stem 18 rotation of approximately ninety degrees (90°).

In an exemplary embodiment, the openings 54 in the moveable disk 20 andthe openings 66 in the fixed disk 22 are configured so that particulatein the shape of a circular ball, having a diameter of one-tenth inch(0.1 in), can pass through the cartridge assembly 10 when the handle andthe stem 18 are in the completely open position at a handle and stem 18rotation of approximately ninety degrees (90°).

One of ordinary skill in the art will now appreciate that the presentinvention provides a cartridge assembly for a faucet that providesimproved flow rate, flow modulation, and particulate passage. Althoughthe present invention has been shown and described with reference toparticular embodiments, equivalent alterations and modifications willoccur to those skill in the art upon reading and understanding thisspecification. The present invention includes all such equivalentalterations and modifications and is limited only by the scope of thefollowing claims in light of their full scope of equivalents.

1.-20. (canceled)
 21. A cartridge assembly for a faucet, the cartridgeassembly comprising: a cartridge shell, the cartridge shell including afirst end and a second end, the cartridge shell having an exteriorsurface, the cartridge shell having an interior, the cartridge shellincluding a pair of openings extending from the interior through theexterior surface between the first end and the second end; a stem, thestem operable to be at least partially disposed within the cartridgeshell; a moveable disk, the moveable disk operable to be disposed withinthe cartridge shell, the moveable disk including a top side and a bottomside, the moveable disk further including a pair of openings extendingfrom the top side through the bottom side, the openings in the moveabledisk being symmetrical across a center line of the openings; and a fixeddisk, the fixed disk operable to be disposed within the cartridge shell,the fixed disk including a top side and a bottom side, the fixed diskfurther including a pair of openings extending from the top side throughthe bottom side, the openings in the fixed disk being symmetrical acrossa center line of the openings; wherein the stem is operable to beconnected to the moveable disk so that rotation of the stem causesrotation of the moveable disk; wherein the bottom side of the moveabledisk is operable to abut the top side of the fixed disk; wherein flowthrough the cartridge assembly flows through the openings in the fixeddisk and through the openings in the moveable disk and exits through theopenings in the cartridge shell; wherein the openings in the moveabledisk and the openings in the fixed disk are configured so that there aretwo zones of control, a first zone is from an open position at a stemrotation of approximately fifteen degrees to an open position at a stemrotation of approximately forty-five degrees and a second zone is fromthe open position at the stem rotation of approximately forty-fivedegrees to an open position at a stem rotation of approximatelyseventy-five degrees; wherein a flow rate through the cartridgeassembly, at three bars of flowing pressure, in the first zone,increases at an average of less than approximately six-tenths gallonsper minute for each stem rotation of approximately five degrees; andwherein an average flow rate through the cartridge assembly, at threebars of flowing pressure, in the second zone, for each stem rotation ofapproximately five degrees, is greater than an average flow rate throughthe cartridge assembly, at three bars of flowing pressure, in the firstzone, for each stem rotation of approximately five degrees.
 22. Thecartridge assembly of claim 21, wherein the openings in the moveabledisk and the openings in the fixed disk are configured so that the flowrate through the cartridge assembly, at three bars of flowing pressure,in the first zone, increases at an average of less than approximatelyfour-tenths gallons per minute for each stem rotation of approximatelyfive degrees.
 23. The cartridge assembly of claim 21, wherein theopenings in the moveable disk and the openings in the fixed disk areconfigured so that the average flow rate through the cartridge assembly,at three bars of flowing pressure, in the second zone, for each stemrotation of approximately five degrees, is at least approximatelyone-hundred seventy-five percent of the average flow rate through thecartridge assembly, at three bars of flowing pressure, in the firstzone, for each stem rotation of approximately five degrees.
 24. Thecartridge assembly of claim 21, wherein the openings in the moveabledisk and the openings in the fixed disk are configured so that the flowrate through the cartridge assembly, at three bars of flowing pressure,does not reach three gallons per minute until an open position at a stemrotation of at least approximately forty degrees.
 25. The cartridgeassembly of claim 21, wherein the openings in the moveable disk and theopenings in the fixed disk are configured so that the flow rate throughthe cartridge assembly, at three bars of flowing pressure, does notreach four gallons per minute until an open position at a stem rotationof at least approximately forty-five degrees.
 26. The cartridge assemblyof claim 21, wherein the openings in the moveable disk and the openingsin the fixed disk are configured so that the flow rate through thecartridge assembly, at three bars of flowing pressure, does not reachfive gallons per minute until an open position at a stem rotation of atleast approximately fifty-five degrees.
 27. The cartridge assembly ofclaim 21, wherein the openings in the moveable disk and the openings inthe fixed disk are configured so that particulate in the shape of acircular ball, having a diameter of approximately six-hundredths inch,can pass through the cartridge assembly when the stem is in a completelyopen position at a stem rotation of approximately ninety degrees.
 28. Acartridge assembly for a faucet, the cartridge assembly comprising: acartridge shell, the cartridge shell including a first end and a secondend, the cartridge shell having an exterior surface, the cartridge shellhaving an interior, the cartridge shell including a pair of openingsextending from the interior through the exterior surface between thefirst end and the second end; a stem, the stem operable to be at leastpartially disposed within the cartridge shell; a moveable disk, themoveable disk operable to be disposed within the cartridge shell, themoveable disk including a top side and a bottom side, the moveable diskfurther including a pair of openings extending from the top side throughthe bottom side, the openings in the moveable disk being symmetricalacross a center line of the openings; and a fixed disk, the fixed diskoperable to be disposed within the cartridge shell, the fixed diskincluding a top side and a bottom side, the fixed disk further includinga pair of openings extending from the top side through the bottom side,the openings in the fixed disk being symmetrical across a center line ofthe openings; wherein the stem is operable to be connected to themoveable disk so that rotation of the stem causes rotation of themoveable disk; wherein the bottom side of the moveable disk is operableto abut the top side of the fixed disk; wherein flow through thecartridge assembly flows through the openings in the fixed disk andthrough the openings in the moveable disk and exits through the openingsin the cartridge shell; wherein the openings in the moveable disk andthe openings in the fixed disk are configured so that there are twozones of control, a first zone is from an open position at a stemrotation of approximately fifteen degrees to an open position at a stemrotation of approximately forty-five degrees and a second zone is fromthe open position at the stem rotation of approximately forty-fivedegrees to an open position at a stem rotation of approximatelyseventy-five degrees; wherein a flow rate through the cartridgeassembly, at three bars of flowing pressure, in the first zone,increases at an average of less than approximately five-tenths gallonsper minute for each stem rotation of approximately five degrees; andwherein an average flow rate increase through the cartridge assembly, atthree bars of flowing pressure, in the second zone, for each stemrotation of approximately five degrees, is greater than the average flowrate increase through the cartridge assembly, at three bars of flowingpressure, in the first zone, for each stem rotation of approximatelyfive degrees.
 29. The cartridge assembly of claim 28, wherein theopenings in the moveable disk and the openings in the fixed disk areconfigured so that the flow rate through the cartridge assembly, atthree bars of flowing pressure, in the first zone, increases at anaverage of approximately three-tenths gallons per minute for each stemrotation of approximately five degrees.
 30. The cartridge assembly ofclaim 28, wherein the openings in the moveable disk and the openings inthe fixed disk are configured so that the flow rate through thecartridge assembly, at three bars of flowing pressure, in the secondzone, increases at an average of approximately six-tenths gallons perminute for each stem rotation of approximately five degrees.
 31. Thecartridge assembly of claim 28, wherein the openings in the moveabledisk and the openings in the fixed disk are configured so that anaverage flow rate through the cartridge assembly, at three bars offlowing pressure, in the second zone, for each stem rotation ofapproximately five degrees, is greater than an average flow rate throughthe cartridge assembly, at three bars of flowing pressure, in the firstzone, for each stem rotation of approximately five degrees.
 32. Thecartridge assembly of claim 28, wherein the openings in the moveabledisk and the openings in the fixed disk are configured so that the flowrate through the cartridge assembly, at three bars of flowing pressure,at the open position at the stem rotation of approximately forty-fivedegrees, is less than approximately four gallons per minute.
 33. Thecartridge assembly of claim 28, wherein the openings in the moveabledisk and the openings in the fixed disk are configured so that the flowrate through the cartridge assembly, at three bars of flowing pressure,does not reach four gallons per minute until an open position at a stemrotation of at least approximately forty-five degrees.
 34. The cartridgeassembly of claim 28, wherein the openings in the moveable disk and theopenings in the fixed disk are configured so that the flow rate throughthe cartridge assembly, at three bars of flowing pressure, does notreach five gallons per minute until an open position at a stem rotationof at least approximately fifty-five degrees.
 35. The cartridge assemblyof claim 28, wherein the openings in the moveable disk and the openingsin the fixed disk are configured so that particulate in the shape of acircular ball, having a diameter of approximately six-hundredths inch,can pass through the cartridge assembly when the stem is in a completelyopen position at a stem rotation of approximately ninety degrees.
 36. Acartridge assembly for a faucet, the cartridge assembly comprising: acartridge shell, the cartridge shell including a first end and a secondend, the cartridge shell having an exterior surface, the cartridge shellhaving an interior, the cartridge shell including a pair of openingsextending from the interior through the exterior surface between thefirst end and the second end; a stem, the stem operable to be at leastpartially disposed within the cartridge shell; a moveable disk, themoveable disk operable to be disposed within the cartridge shell, themoveable disk including a top side and a bottom side, the moveable diskfurther including a pair of openings extending from the top side throughthe bottom side, the openings in the moveable disk being symmetricalacross a center line of the openings; and a fixed disk, the fixed diskoperable to be disposed within the cartridge shell, the fixed diskincluding a top side and a bottom side, the fixed disk further includinga pair of openings extending from the top side through the bottom side,the openings in the fixed disk being symmetrical across a center line ofthe openings; wherein the stem is operable to be connected to themoveable disk so that rotation of the stem causes rotation of themoveable disk; wherein the bottom side of the moveable disk is operableto abut the top side of the fixed disk; wherein flow through thecartridge assembly flows through the openings in the fixed disk andthrough the openings in the moveable disk and exits through the openingsin the cartridge shell; wherein the openings in the moveable disk andthe openings in the fixed disk are configured so that there are twozones of control, a first zone is from an open position at a stemrotation of approximately fifteen degrees to an open position at a stemrotation of approximately forty-five degrees and a second zone is fromthe open position at the stem rotation of approximately forty-fivedegrees to an open position at a stem rotation of approximatelyseventy-five degrees; wherein, a flow rate through the cartridgeassembly, at three bars of flowing pressure, in the first zone,increases at an average of less than approximately four-tenths gallonsper minute for each stem rotation of approximately five degrees; andwherein, an average flow rate through the cartridge assembly, at threebars of flowing pressure, in the second zone, for each stem rotation ofapproximately five degrees, is at least one-hundred seventy-five percentof an average flow rate through the cartridge assembly, at three bars offlowing pressure, in the first zone, for each stem rotation ofapproximately five degrees.
 37. The cartridge assembly of claim 36,wherein the openings in the moveable disk and the openings in the fixeddisk are configured so that the flow rate through the cartridgeassembly, at three bars of flowing pressure, does not reach threegallons per minute until an open position at a stem rotation of at leastapproximately forty degrees.
 38. The cartridge assembly of claim 36,wherein the openings in the moveable disk and the openings in the fixeddisk are configured so that the flow rate through the cartridgeassembly, at three bars of flowing pressure, does not reach four gallonsper minute until an open position at a stem rotation of at leastapproximately forty-five degrees.
 39. The cartridge assembly of claim36, wherein the openings in the moveable disk and the openings in thefixed disk are configured so that the flow rate through the cartridgeassembly, at three bars of flowing pressure, does not reach five gallonsper minute until an open position at a stem rotation of at leastapproximately fifty-five degrees.
 40. The cartridge assembly of claim36, wherein the openings in the moveable disk and the openings in thefixed disk are configured so that particulate in the shape of a circularball, having a diameter of approximately six-hundredths inch, can passthrough the cartridge assembly when the stem is in a completely openposition at a stem rotation of approximately ninety degrees.